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CONTENTS
Introduction
DCS Main
Components
DCS Graphics
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Process Control Elements
Process control :defined as any operation that regulates some physical Parameters for process
Process
Input Output
Final Control
Sensor Control System
Element
Sense/Measure
Set Point
Layer Of Protections
What are the Layer Of Protections?
•Multiple Layers •Independent safety barriers
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Layer Of Protections
What are the Layers Of Protections?
Layer Of Protections
Community Emergency Response
Emergency Response plan
Mitigation Layers Fire and Gas Systems
Physical Containments (Dikes)
Mechanical Relief Devices
Safety Instrumented Systems
Alarm and operator intervention
Prevention Layers
Basic Process Control System
Inherent safe Process
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Layer OfControl
Integrated Protections
and Safety System ICSS
Mitigation Layers Fire and Gas Systems
Mechanical Relief Devices
Safety Instrumented Systems
Alarm and operator intervention
Prevention Layers
Basic Process Control System
Introduction
Control Systems
PLC System
Programmable Logic Controller
A ruggedized industrial computer used for automating electromechanical
processes
Designed for real-time control of machinery and production lines.
PLCs are traditionally associated with discrete manufacturing
.
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Introduction
Control Systems
PLC System
Modern high-performance PLCs (e.g., Siemens S7-1500,
Rockwell ControlLogix, Emerson PACSystems) now support:
Analog I/O & PID control (critical for temperature, pressure, flow
regulation).
High-speed processing for complex control algorithms.
Redundancy & fault tolerance (traditionally a DCS strength).
Integration with SCADA for plant-wide monitoring
PLC Control System Implementation Example
Introduction
Control Systems
DCS System
Distributed Control System
A networked control system for large, complex processes (e.g., oil refineries, chemical
plants)
Uses multiple controllers distributed across the plant for centralized monitoring &
decentralized control.
Optimized for continuous process automation with high reliability and redundancy.
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Introduction
Control Systems
DCS System
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Introduction
Control Systems
SCADA (Supervisory Control and Data Acquisition)
A software-based system for monitoring & controlling industrial processes over large
distances (e.g., power grids, water treatment).
Collects real-time data from sensors/PLCs and provides HMI (Human-Machine Interface) for
operators.
Focuses on data visualization, alarms, and historical logging rather than direct control.
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Introduction
Control Systems
SCADA (Supervisory Control and Data Acquisition)
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Introduction
Control Systems
SCADA (Supervisory Control and Data Acquisition)
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Introduction
Control Systems
BASIC PROCESS CONTROL SYSTEM
Function: BPCS are designed to control the normal operations of a process. They manage the
routine control of processes, ensuring that everything runs smoothly and efficiently.
Operation: These systems are active and dynamic, frequently responding to various digital and
analog inputs and outputs. This makes most failures self-revealing
Changes: Modifications to BPCS are common to maintain accurate process control
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Introduction
Control Systems
BASIC PROCESS CONTROL SYSTEM & Safety instrumented system
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Introduction
Control Systems
1.Safety Instrumented Systems (SIS):
Function: SIS are designed to monitor and maintain process safety. They are typically passive and only
activate in response to specific conditions that could lead to hazardous events
Operation: Since they are not frequently called into operation, SIS components must have diagnostics to
ensure they are functioning correctly
Independence: SIS should be separate from BPCS to ensure that a failure in the control system does not
compromise the safety system
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Introduction
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Introduction
Terminologies used in a control loop are :
PV – Process Variable or Input
SV – Set Variable/ Set Value
MV – Manipulated Variable or Output
I/P – Current to Pneumatic signal
converter converts 4-20 mA
current signal to 0.2 to 1
Kg/cm2 or 3-15 psi
pressure signal
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Introduction
PID Controller
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Introduction
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Introduction
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DCS System Main Components
1. Field Devices (Sensors & Actuators)
•Sensors (Inputs):
• Temperature (RTD,
Thermocouple)
• Pressure (Transmitters)
• Flow (Flowmeters)
• Level (Level Sensors)
• Analytical (pH, Conductivity)
• Digital Inputs (Switches, Proximity
Sensors)
•Actuators (Outputs):
• Control Valves
• Motor Drives (VFDs)
• Solenoid Valves
• Relays
Sensor/ Input Final
Controller/DCS/PLC Element/Actuator
Device
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DCS System Main Components
2. Input/output (I/O) Modules
•Analog Input (AI) Modules – Process 4–20 mA, 0–
10V, RTD signals.
•Analog Output (AO) Modules – Send 4–20 mA signals
to control valves/VFDs.
•Digital Input (DI) Modules – Read ON/OFF signals
(e.g., pump status).
•Digital Output (DO) Modules – Send ON/OFF
commands (e.g., start/stop motors).
•Specialty I/O Modules – Pulse inputs, HART
communication, etc.
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DCS System Main Components
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DCS System Main Components
3. Central Processing Unit (CPU) / Controller
•Executes control logic (PID, sequence control).
•Processes I/O data and communicates with other components.
•Often redundant (dual CPUs for high availability).
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DCS System Main Components
Field Devices (Sensors & Actuators)
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DCS System Main Components
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DCS System Main Components
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DCS System Main Components
CPU DCS YOKOGAWA
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DCS System Main Components
4. Communication Processors & Networks
•Communication Processors:
• Manage data exchange between controllers, I/O, and
HMIs.
• Support protocols like Modbus, Profibus, Ethernet/IP,
Foundation Fieldbus.
•Network Components:
• Switches, Gateways, Routers
• Redundant Ethernet (Dual-ring topology) for reliability.
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DCS System Main Components
5. Human Machine Interface (HMI) /
Operator Stations
•Function:
• Real-time process visualization
(mimic diagrams, trends).
• Alarm management & operator
control.
•Types:
• Desktop HMIs (e.g., Siemens WinCC,
Honeywell Experion).
• Touchscreen Panels
• Web-based HMIs (for remote
access).
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DCS System Main Components
5. Human Machine Interface (HMI) / Operator Stations
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DCS System Main Components
5. Human Machine Interface (HMI) / Operator Stations
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DCS System Main Components
6. Engineering Workstation (EWS)
•Used for:
• Configuring control logic.
• Programming PLC/DCS (e.g., Function Block
Diagrams, Ladder Logic).
• System diagnostics & maintenance.
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DCS System Main Components
6. Engineering Workstation (EWS)
•Used for:
• Configuring control logic.
• Programming PLC/DCS (e.g., Function Block
Diagrams, Ladder Logic).
• System diagnostics & maintenance.
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DCS System Main Components
7. Historical Data Storage & Trends
•Historical Database Server – Stores process data .
•Trending Tools – Analyze historical data for optimization & troubleshooting.
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DCS System Main Components
8. OPC Server (Open Platform Communications)
•Enables interoperability between DCS and:
• SCADA
• MES/ERP systems
• Third-party software
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DCS System Main Components
9. System Integration Components
•Gateways – For legacy system integration (e.g., Modbus to OPC UA).
•Firewalls – Cybersecurity for DCS networks.
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DCS System Graphics
YOKOGAWA DCS for Examples
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YOKOGAWA DCS for Examples
1. HIS (Human Interface Station)
Definition: The operator workstation in Yokogawa’s Centum VP/CS DCS, providing a
graphical interface for monitoring and controlling processes.
Key Features:
Displays mimic diagrams, alarms, and trends.
Allows operator inputs (e.g., setpoint changes, manual overrides).
Integrates with engineering stations for configuration.
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YOKOGAWA DCS for Examples
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CENTUM VP USER INTERFACE
Operator Keyboard
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CENTUM VP USER INTERFACE
User Graphic interface
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CENTUM VP USER INTERFACE
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CENTUM VP USER INTERFACE
The System Message Banner is always displayed at the top of the display, and presents alarm information
and provides instant access to frequently used views and priority features.
System Message Banner will never be hidden behind other windows
System Alarm:
The system alarm notifies operator of the abnormalities in the hardware and communication errors. The
type and contents of the system alarm are predetermined.
Process Alarm:
The process alarm notifies operator of the occurrence and recovery of abnormality in the process. The
type and contents of the process alarm are predetermined
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ALARM STATUS
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PROCESS ALARM STATUS
The alarm priority is as shown:
1. IOP/OOP
2. HH/LL
3. HI/LO
4. DV+/VEL+
5. MHI/MLO
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2. Faceplate
•Definition: A standardized pop-up window in Yokogawa’s HIS that
displays critical parameters and controls for a specific field device
(e.g., valve, pump).
•Contents:
• Process Variable (PV), Setpoint (SP), Output (OP).
• Alarms, mode (Auto/Manual), and manual override buttons.
•Purpose:
• Quick operator access to device control.
• Consistent interface across the DCS.
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OPERATION MARK
The operation mark is a mark with comment attached to an instrument faceplate.
It can temporarily change the operation status (permission/prohibition) of the
instrument faceplate.
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DATA ENTRY DIALOG CALL
BUTTON
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OPERATIONS ON INSTRUMENT FACEPLATE
The following operations may be performed on the
instrument faceplates displayed in the active window:
SV Operation
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OPERATIONS ON INSTRUMENT FACEPLATE
The following operations may be
performed on the instrument
faceplates displayed in the active
window:
Block mode change Operation
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OPERATIONS ON INSTRUMENT FACEPLATE
The following operations may
be performed on the
instrument faceplates
displayed in the active
window:
Data Entry Operation
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MAN (Manual Mode)
To disable the effect of the controller block and
bypass its result with assigning a manual output
directly to the final control element.
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AUT (Automatic Mode)
The controller block will perform the function it
is designed for according to the logic and
sequence without any interference.
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CAS (Cascade Mode)
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CAS (Cascade Mode)
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INITIALIZATION MANUAL MODE (IMAN)
In a cascade loop, if the cascade is broken by taking the secondary
controller from CAS to either AUT or MAN mode, IMAN appears as
the mode sub status of the primary controller.
IMAN indicates that
Cascade loop is broken
Primary controller is bypassed
Primary controller cannot be operated due to
SV tracking.
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Trend (Historical/Real-Time Trend)
•Definition: A graphical representation of process variables over time, used for
analysis and troubleshooting.
•Types:
• Real-Time Trend: Live data updates (e.g., current temperature
fluctuations).
• Historical Trend: Archived data (stored in a historical database like
Exaquantum).
•Uses:
• Identifying process deviations.
• Compliance reporting.
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